Our services cover the complete spectrum of activities from concept to commissioning with single point responsibility.

Services offered

 
• Process Technology Transfer
• Projects Completed under our consultancy.
• Projects in progress under our consultancy.
• Plant Details
• Scope of detailed Engineering & Design.
• Detailed Engineering Services
• Project Management and Planning
• Inspection/Expedition
• Procurement Assistance
• Construction Management and Overall Supervision (Optional)
• Services During Commissioning
• Documentation
• Exclusion

Facilities Available

 

Office :	800 Sq. Area
CAD Systems :	Pentium 100 - 4 Nos.  Pentium 60 - 3 Nos.  HP 350C - Plotter  Fax, DT-670 C, CAD Caligra,  Drafting Boards - 4 Nos.
Man Power :	Engineers -  4 Full Time CAD Operators - 6 Nos. Full Time Manual Draftsman - 2 Nos. Full Time Associates -  M/s. Spark Consultants R. V. Dalvi & Associates Alfa Engineers

 

We have with us vast data bank on bulk drugs and pharmaceuticals (process and engineering) which will be useful for execution of projects in bulk drug and pharmaceuticals industries at faster rates compare to other consultants.

Projects Completed under our consultancy

 

NAME OF COMPANY	PRODUCTS	COST OF PROJECT	SCOPE
M/s. Kopran Ltd., Bombay	Multipurpose Bulkdrug Plant	US$ 4.16 million  Rs. 1500 Lacs.	Detailed Engg.
M/s. Kopran Ltd., Bombay.	Automatic lines for Dry Syrup, Capsules, Tablets	US$ 4.16 million  Rs. 1500 Lacs.	Detailed Engg.
M/s. Dee Pharma Ltd. Bhiwadi.	Sterile Bulkdrug Plant  Plant & Sterile Automatic Vial Filling For Antibiotics	US$ 3.61 million  Rs. 1300 Lacs.	Process know-how, Detail Engg., Commissioning (Turn Key)
M/s. Dee Pharma Ltd. Sikandarabad.	Automatic Sterile Liquid lines for Dexamethazone, Analgin	US$ 2.78 million  Rs. 1000 Lacs.	Detailed Engg.
M/s. Armour Chemicals Ltd. Bombay.	Sterile Vial Filling line for Sodium Ampicillin 10 Lakhs/Month. (Semi Automatic Line)	US$ 0.25 million  Rs. 90 Lacs	Detailed Engg.
M/s. Armour Chemicals Ltd. Bombay.	Capsule filling line (Semi Automatic Lines) 100 Lakh Capsules / Shift / Month for Pencillin group of drugs.	-	Detailed Engg.
M/s Kopran Ltd. Mahad.	Multipurpose Sterile Bulk drug plant for Sodium Amoxycillin, Cefazoline Sod., Cefatoxime Sod., Ceftriaxone Sod., Cloxacillin Sod.	US$ 0.83 million  Rs. 300 Lacs.	Detailed Engg.
M/s EPIC Limited.  New Bombay.	Ethofumesate & metamitron 300 Tonns/Annum	US$ 0.83 million  Rs. 300 Lacs.	Detailed Engg.
M/s. Pharmasia Ltd.	Pefloxacin Mesylate	US$ 0.17 million  Rs. 60 Lacs.	Process know-how Engg. & commissioning (Turn Key)
M/s. Diamond Dye Chem Ltd., Bombay.	Optical Whitener Plant	US$ 2.78 million  Rs. 1000 Lacs.	Detailed Engg
M/s. Vedant Dye-Stuff Pvt. Ltd. Taloja.	E.O.U. for dyes	US$ 0.42 million  Rs. 150 Lacs	Detailed Engg.
M/s. Surya Medicare Ltd. , Area Chandigarh.	Sterile lyphylised Anti-biotic Plant, Sterile vial filling line, Crystalline Ampicillin Sodium, Crystalline Amoxycillin Sodium	US$ 5.56 million  Rs. 2000 Lacs	Process know, Basic Engg, detailed Engg. (Turn Key)
M/s.Ind-Swift Lab. Ltd. Chandigarh.  for U.S.F.D.A. approval	Nalidixic Acid,Erythro mycin estolate, Betamethasone,Dompe- idone, Omeprazole,7-ACA derivatives, Cefatoxime Sod.,Ceftriaxone Sod.	Rs. 3000 Lacs	Process know-how, Detailed Engg, commissioning (Turn Key)
M/s. Neon Antibiotics Ltd. Bombay.	Anti Cancer, Bulk Drug	US$ 0.13 million  Rs. 60 Lacs	Detailed Engg.
M/s. Aloka Exports	Textile Printing	US$ 0.65 million  Rs. 300 Lacs	Detailed Engg.
Neon Lab.Ltd. Palghar	Low volume sterile liquid & powder filling facilities	US $ 1.0 million	Total engg. services, commissioning
Granules India Ltd. Hyderabad	Guaifenesin 30 TPM / Folic acid 6 TPM	US $ 1.0 million	Process Engg., project engg. , Total revamping of existing facilities to enhance productivity
M/s. Sambiotech Ltd. Chandigarh	Plant for Ampicillin Sodium, Amoxycillin Sodium, Cloxacillin, Cefadroxyl and its intermediates.	US $ 8.33 million Rs. 3000 Lacs	Process know how, Detailed Engg.
Elder Pharmaceuticals Ltd. Patalganga.	Multi purpose bulk drug plant For microlides & refecoxib, celicoxib	US $ 2.83 million Rs. 1300 lacs	Process Engg. Detailed Enggs.
Vasant Chemicals Ltd. Hyderabad .	Speciality Chemicals	US $ 0.7 million Rs. 300 lacs	Detailed Engg, Basic Engg, Validation as per USFDA.
Neon Labs Ltd. Shirgaon	Halothene, Isoflurane filling lines	US $ 0.7 million Rs. 300 lacs	Detailed Engg, Basic Engg, Validation as per cGmp.

 

Projects in progress under our consultancy

 

NAME OF COMPANY	PRODUCTS	COST OF PROJECT	SCOPE
M/s. Aristo Pharma Ltd., Bombay	Sterile Cefalosporines	US$ 0.56 million  Rs. 200 Lacs.	Turnkey (Process know-how, Detailed Engg., Commissioning)
M/s. Amtek Lab Ltd., New Delhi.	Capsules & Tablets Dry syrup	US$1.11 million  Rs. 3000 Lacs.	Detailed Engg, Basic Engg, Validation as per USFDA.
Surya Pharmaceuticals ltd. Chandigarh	Sterile bulk Cefalosporines/ Betalactum products	US $ 6.5 million	Turnkey (process know-how, detailed Engg., Commissioning)
Surya Pharmaceuticals Ltd. Chandigarh	Pharma ceuticals Capsules, Tablets, dry syrup, dry sterile powder filling, liquid syrup.	US $ 6.5 million Rs. 3000 lacs	Detailed Engg., Basic Engg., Validation as per USFDA.
Vedant drugs & fine Chemicals ltd. Ambernath	Multi purpose drug intermediate/ API products	US $ 1.1 million Rs. 500 lacs	Detailed Engg,Basic Engg, Validation as per USFDA.
Active Fine Chemicals Ltd. Bangladesh	Multi purpose drug plant for API products	US $ 1.96 million Rs. 900 lacs	Turn Key (process know-how detailed Engg.
Square Pharmaceuticals Ltd. Bangladesh	Multi purpose plant for API products	US $ 2.0 million Rs. 918 lacs	Turn Key (process know-how detailed Engg.
Omni Actives Healthcare Technologies Pune	Nutraceuticals plant	US $ 1.7 million Rs. 700 lacs	Detailed Engg,Basic Engg, Validation as per USFDA.

 

 

Plant Details

The Process Plant, for which APCE shall provide their services as outlined in Clause 2.00 to 5.00 of this Proposal shall be in regard to the following facilities :

Site & Location

The Location of the proposed plant shall be at -------------------.

Process Equipment

The Process Plant shall have the equipment as per Facilities Available.

Civil/Structural Work

These shall be as follows :

- Process Plants
- Warehouses
- Office/Lab/Canteen
- Hazardous Area
- Tank farm Area
- Utility/Workshop bldg.
- Plot Plant
- Misc. Buildings

Utilities

Utilities required for the plant shall be as follows :

- Boilers
- Cooling Tower
- Chilled water
- Chilled Brine
- DM Water
- Hot Water
- Process Water
- Domestic Water

HVAC

Necessary HVAC will be as per Bulk Drug Norms for a Bulk Drug Plant.

Electricals

The requirements of power shall be worked out by APCE, which will be drawn from 11/33 kV feeder.

Solvent Recovery Plant

Solvent Recovery units for recovery of process solvent. The works towards this shall be awarded by CLIENT on turnkey basis for supply, erection and commissioning of the plant or only supply. Necessary utility connections for the plant & civil foundations & structural work will be designed by APCE for these plants.

Instrumentation

The Instrumentation will be both PLC & pneumatic control & shall cover all instrumentation work for the Project.

Effluent Treatment

APCE shall provide effluent characterization,Quantum, in co-ordination with CLIENT. Based on the above information job will be given on turn-key basis for design, supply, erection & commissioning of the plant.

Fire Fighting

Necessary Fire Fighting System shall be designed for the Process Plant as per the statutory & TAC requirements.

Piping

All inter-connecting piping for the various equipment in the Process Plant as well as Yard Piping between the Utilities, Solvent Recovery plant and tank farms. The piping will also include complete utility distribution within the process buildings.

Insulation & Painting

This shall be carried out as per the requirement for the Process Plants.

Mechanical Completion

Mechanical Completion shall mean that the PLANT has been installed, satisfactorily tested and is physically complete except for minor items which do not prevent the PLANT from being safely charged with process fluids/materials.

Scope of Detailed Engineering & Design.

 

	Preparation of Chemical Reaction Data Sheets.
	Preparation of Process Flow Diagram.
	Preparation of Material & Energy Balances.
	Selection of All Materials of Construction.
	Sizing of all equipment's.
	Design of process equipment's like Reactor, Tanks, Heat Exchanger, Agitator, Distillation Columns, Absorbes, etc.
	Preparation of Specification Sheets (Process) for plant & machinery.
	Preparation of Specification Sheets for all raw materials/Finished Products.
	Preparation of Master Plan of the project.
	Preparation of P & I Diagrams for
	Each process (manufacturing) plant. Utility section. Off-sites facilities for Solid & Liquid storage. Effluent Treatment plant (Scheme Only). Material Handling System.
	Preparation of Lay-Out Drawings & Loading Data for
	Each manufacturing plant. Utility Section Off-sites. Raw Materials/Finished Goods storage (Goodman) section. Explosive Area Pipe Rack/Cable Trench - Loading Data.
	Preparation of Specification Data Sheet with Necessary Drawings for
	Each Fabricated equipment of Process & Utility Sec. Each bought out machinery of Process & Utility Sec. Each pipe, valve & fittings of entire project. (i.e. all instruments shown in P & I Diagram) Each painting and insulation of pipes & equipment's
	Giving suggestion/confirmations for selection of Materials of construction (MOC) for each equipment, valve & fittings.
	Preparation of Detailed Bar charts for project execution.

 

A. Detailed Engineering Services

1. Process Engineering

Prepare/Carry out the following :

1. Complete utility requirements for the process units& offsites together and work out capacities for the utility units.
2. Prepare Equipment list for process, utilities & offsites.
3. Prepare scheme for all utilities & prepare data sheets for offsites and utilities equipment's.
4. Prepare P & I diagramme for all utilities.
5. Basic layouts for offsites and utilities.

2. Mechanical Engineering

The following shall be carried out for the manufacturing equipment as well as utility  and offsite equipment.

Prepare the following :

1. To prepare detailed equipment layouts in plans & elevations for various process & utility sections.
2. Collect design parameters and prepare specifications for packaged units.
3. To prepare mechanical data sheets/specifications for all process equipment's.
4. To recommend vendors for various fabricated equipment's & review vendors drawings and provide comments.
5. Prepare contract documents for the installation of equipment, invite tenders, analyse and recommend suitable contractors.

3. Architectural/Civil/Structural Engineering :

1. Scrutinise soil investigation report provided by CLIENT & advise if any further soil investigation work is necessary.
2. Provide assistance in site development.
3. Prepare the following :
1. Layout covering the location & principal arrangement in the Plant (Plot plan) keeping in view the future expansion.
2. Architectural/Civil/Structural designs & drawings for building, foundations, superstructures,steel structures, platforms, stairs, structural supports for equipment & pipes, pipe racks, etc, within the plant.
3. Design and drawings for equipment foundations.
4. Designs and drawings for trenches, drains and water supply etc.
5. Prepare bills of quantities and specifications for all construction material including Cement and Steel.
6. Prepare Tender Document for Civil/Structural work and float to 4-5 qualified parties.
7. Carry out technical appraisal of quotations received and recommend suitable schedules.
8. Review contractors fabrication drawings for structures & bar-bending schedules.
9. Prepare contract documents for civil works to be executed by CLIENT's civil contractor.

4. Piping Engineering

Prepare/carry out the following :

1. Pipe sizing and prepare specifications for all piping work including for valves, fittings and other accessories. plant.
2. Piping General Arrangement drawings.
3. Isometrics for all pipelines above 2" and for all stainless steel pipes above 1".
4. Stress analysis wherever necessary.
5. Drawings required by boiler inspector and other statutory bodies.
6. Piping bulk bill of materials with specifications for all pipes, valves fittings and other accessories.
7. To prepare Tender document for piping, fabrication and installation work to be carried by CLIENT's contractor.
8. To invite tenders for piping installation work, analysis them and recommend suitable party.
9. To prepare contract document for piping installation.

5. Electrical Engineering :

 
1. To prepare specification, bills of materials and approve vendor's drawings wherever applicable for :

- Transformer
- HT/LT Switchgear
- Power Control Cables
- Lighting Fixtures
- Motors
- Push buttons
- Sub-station equipment's
2. To carry out and prepare :

- Load calculations and single line and control wiring diagram.
- Design layout for outdoor HT yard and substation.
- Power, earthing and lighting protection layout.
- Cable Schedule and layouts, cable trays/trenches layout.
- Lighting layout for the whole Plant including lighting for yard and structures.
- Emergency power supply and distribution including internal provision in main switchgear to switch over to emergency power.
3. Preparation of Tender documents corresponding to Electrical Contracting work including bill of quantities and specifications.The tenders will be prepared on the basis of awarding work on item rate contract.
4. To invite bids for 4-5 No. Electrical Contractors. To carry out bid analysis of tenders received by SWGL and recommend suitable contractor.
5. Necessary statutory drawings required for submission to Electrical Inspectorate and State Electricity Board.

6. Instrumentation :

1. Prepare Instrument list grouping associated sensing, transmitting & control elements.
2. To prepare data sheets for all instruments based on basic scheme and specifications.
3. Specifications for installation of instruments.
4. To prepare material take-off & prepare document for installation work.
5. Floating of enquires Carry out technical appraisal of quotations & recommend suitable vendors.

7. Insulation & Painting :

1. Select type of insulation material.
2. Prepare specifications and Material Take Off.
3. Carry out technical appraisal of quotations and recommend suitable vendors.
4. Prepare document for supply and installation of insulation and painting to be executed by CLIENT's contractor, analyse bids and recommend suitable contractor.

8. Effluent Treatment Plant :

Generation of the basic data. On liquid, solid, gaseous that will be generated within the Plant, APCE will prepare Tender document providing sufficient details for CLIENT to invite Turnkey Contract proposals from competent parties for design, supply erection & commissioning of the Effluent Treatment Plant. Further, APCE will carry out Technical analysis of Turnkey bids received and recommend suitable pary. The Services under this will be restricted to the technical work towards accumulation, treatment and disposal at a central place, of waste materials and effluents generated within the Plant. Actual obtaining clearance from the Pollution Control Board will be the responsibility of CLIENT.

9. Solvent Recovery Plant :

APCE scope of services towards these will be to design the systems, equipment's and prepare drawings for Civil/Structural foundations, utilities connections only, layouts, P & I diagrams, safety etc.

10. Fire fighting and Safety Alarm System :

1. Based on the basic requirements of Fire Fighting Systems, APCE shall co-ordinate all activities involved, to implement the same as per insurance company/statutory requirement.Civil buildings should also be as per specific requirement to meet Fire Hazards. Such activities shall include preparing and issuing tender document for turnkey supply of Fire Fighting System to selected vendors.
2. To receive and evaluate bids/offers received, prepare Techno- Commercial analysis and recommend turnkey Contractor to supply, install and commission Fire Fighting System.

B. Project Management and Planning

1. Project Management :

1. Prepare coordination procedure giving details of the following :

1. Project organisation (relationship between suppliers / Licensor / Contractors APCE & CLIENT.
2. Project reference & addresses.
3. Communication between the Owner and the Consultant and others,
4. Information to be obtained from the owner.
5. Minutes of meetings.
6. Progress Reports.
7. Change notice procedure.
8. Equipment coding and numbering system.
9. Documents issued to CLIENT & approvals by CLIENT.
2. Distribute work to other departments/groups within the APCE's organisation.
3. Review the data provided to APCE, discuss in detail and determine with Owner the general parameters & design standards and establish the long delivery items.
4. Assist Owner (limited to technical assistance) in obtaining necessary statutory approvals such as Boiler Inspector, Factory Inspector and Electrical Inspector, Pollution Control Board.

2. Planning :

1. Prepare a Computerised Programme indicating critical (milestone) events considering the overall project completion.
2. Prepare regular activity schedule defining the work required to be done during a specific period based on the overall network diagram.
3. Prepare monthly planning reports indicating (disciplinewise) planned and actual progress of engineering, design, procurement and construction.

C. Inspection/Expediting

Scope of Inspection will be as follows for equipment/material purchased in India.

1. Inspection :

1. For Storage tanks & uncoded vessels

1. Material Identification.
2. Final dimensional check up and hydrostatic test.
2. Site fabricated tanks and uncoded vessels

These will be indicated at site.
3. For pressure vessels and columns

Conduct stagewise inspection limited to :
        1. Identification of materials
        2. Welding procedures and welders performance qualifications.
        3. Percentage of fit ups and alignments.
        4. Crack detection examination/radiography where applicable.
        5. Full dimensional and visual check including arrangement of including internals and trays  where applicable.
        6. Hydrostatic testing.
4. For heat exchangers

Conduct stagewise inspection limited to :
        1. Shells - As mentioned in Para (C) above.
        2. Tube Bundles.
            Identification of materials :

 

Welding procedure and welders performance qualification in case of welded tube exchangers.

Crack detection of tube ends, tube welds and tube sheets where applicable.

Dimensional check up and hydrostatic testing.

 

5. For Pumps, Fans, Blowers

Conduct final inspection and witness performance tests wherever applicable and necessary as per APCE.
6. For piping materials

Conduct at random, inspection of piping material such as valves, fittings and pipes.

(Note : Consultant may waive inspection of piping material based on manufacturer's test certificates, vendors performance, organisation and the type of item under consideration)

7. For instruments

Conduct final inspection of instrument at random.
8. Electricals

Conduct inspection of electrical items at random.
9. Package Units

Conduct final hydraulic tests and dimensional check up for package units, Stagewise inspection is excluded.
Main items such as condensers, etc. shall be subject to final hydraulic test.
Issue despatch inspection to vendors for despatching equipment/materials.

2. Expediting

a. Home office expediting

- Carry out expediting from APCE's office limited to expediting of main vendors :

- Frequency of expediting shall not be more than once a fortnight in normal circumstances.

- Prepare and update periodically equipment and material progress schedule (indicating

orders placed, progress of manufacture and deliveries)

b. Field Expediting

Carry out expediting by visiting vendors premises and workshops as and when necessary.

D. Procurement Assistance

(Limited to indigenous equipment's and material)

APCE shall provide following services for Process, Utilities & Offsites Equipment & Materials where APCE are involved.

1. To decide in consultation with CLIENT on parties to whom enquiries are to be forwarded for specific items. APCE are also to prepare formal enquiry letters alongwith necessary specifications and forward the same to parties concerned for obtaining bids.
2. To receive all quotations and to carry out bid evaluation.
3. During the evaluation, to hold discussions with bidders to clarify all technical and general commercial matters, if required.
4. To study quotations received for all items and to prepare comparative charts.
5. To recommend vendors on whom orders may be placed for specific items.
6. To conduct detailed discussions with the possible suppliers to finalise all conditions of the order.
7. To obtain all technical drawings/documentation, including operating manuals from Vendors/Suppliers as per purchase order conditions.
8. Further, to obtain suppliers guarantees for the equipment being supplied.

NOTE : Preparation of draft or final Purchase Orders shall be excluded from APCE's scope of services.

E. Construction Management and Overall Supervision (Optional)

1. Provide the project engineer at the Site.
2. To carry out Planning of construction work, items & disciplinewise.
3. Organise site to ensure that the work is carried out in safe and workmanlike manner in accordance with the specifications and to the programme.
4. Check, certify quantities and rates in contractors bills.
5. Assess labour force required to meet the site are as per programme and ensure that contractors deploy the required force and construction equipment.
6. Conduct trade tests for craftsmen including material fitters, pipe fitters and instrument fitters.
7. Supervise unloading of equipment at site.
8. Render assistance in inspection of materials/equipment's, material and report damage, if any at site. (This shall be done only after Consultant established organisation at site)
9. Render assistance in hiring construction equipment's and purchase of consumables, wherever necessary.
10. Witness and certify performance of packages/units jointly with CLIENT commissioned by vendors commissioning engineers.

 

Note : The above work shall be performed by APCE's site staff in past or in full depending upon the number of APCE site staff deputed at site.

F. Services During Commissioning

Providing during commissioning the services for construction supervision engineers to supervise such modification of the plant as may be required by the CLIENT's Commissioning engineers. (Mechanical Commissioning)

Note : Services in 3.05 and 3.06 can be provided on Man-month basis, if required.

Documentation

1. APCE will provide to CLIENT, following prints of Detailed Engineering Drawings, specifications & Tender Documents :

 

Drawings :
- Two sets of prints for comments/approval.
- Four sets of prints marked "Good for Construction" after incorporating comments from CLIENT.

Data/Specification Sheets :
- Two sets of prints for comments/approval of CLIENT.
- Four sets of prints after incorporating comments from CLIENT for enquiry purpose.

Tender Documents :
APCE will provide upto six sets of Tender Documents to CLIENT for obtaining bids from Contractors. However, APCE shall be free to charge Contractors a nominal cost towards these documents. Further after finalisation of Contract, APCE will provide three copies of final contract document finalised with the selected Contractor.

Reproducibles :
One reproducible for each of the final drawings/specifications/data sheets.

NOTE : More prints can be provided, if required, at an additional cost which can be discussed at a later stage.

Exclusion (from scope of work)

The following shall be excluded from APCE's scope of work :

 
1. Matters relating to any import formalities such as custom clearance etc. and any payments to be made to these agencies.
2. Obtaining statutory approvals from all Local, Site and Central Authorities. However, APCE will provide technical assistance to CLIENT for obtaining these approvals, Any payments to be made to these bodies will also be beyond APCE's scope of work.
3. Preparation of Fabrication drawings for fabricated equipment which are normally prepared by equipment Suppliers. APCE shall however, check and approve these drawings.
4. Interior furniture layouts/interior decoration for the plant administration buildings etc.
5. Preparation of model for the plant. However, APCE can organise this form outside party at additional cost to CLIENT.

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[Home] [Products] [Services] [Turnkey Projects] [Feedback] Gr.Floor, Radha Apartment, Deen Dayal Road, Vishnu Nagar, Dombivli (W) - 421 202, Maharashtra, INDIA. TEL : 00-91-251-2481942  FAX : 00-91-251-2486886 E-mail - anjo@giasbm01.vsnl.net.in

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